Tailing pond remediation

ABSTRACT

Various embodiments of the present disclosure can include a system for filtering of contaminated fluid. The system can include a fiber manufacturing plant. The system can include a filter system which utilizes a fiber filter produced in the fiber manufacturing plant to clean and recycle a contaminated fluid.

FIELD OF THE INVENTION

Embodiments of the present disclosure relate generally to a method, apparatus and system for the remediation and potential elimination of tailing ponds that can result from surface mining of natural resources such as bitumen or unconventional oil.

BACKGROUND

The surface mining hydrocarbon recovery process in locations such as the oil sands of Alberta Canada has proven to be an effective way of recovering fossil energy, however, the process is not without negative issues. One of the undesirable traits is a larger disposal requirement of a tailing solution that is the result of the bitumen separation process from the mined ore. The most widely used surface mined bitumen separation process is the Clark Hot Water Extraction Process. That process produces approximately 5 to 12 barrels of waste fluid for every barrel of oil equivalent derived from the bitumen ore. The majority of this fluid is deposited in tailing ponds and is to some level toxic. The ponds quickly settle out the sands and heavy debris allowing for 7 barrels of recoverable fluid per 12 barrels of waste fluid produced for every barrel of oil equivalent. This recovered fluid can be re-used in the bitumen separation process in a reasonable amount of time. Unfortunately, the balance of the fluid is contaminated with “fines” which are made up of clay and other particles that are generally below 44 microns in size. These particles for numerous reasons can stay in suspension for up to thousands of years making these ponds an extreme ecological liability. Many filtering methods have been tried to recover the balance of the recyclable fluids from the ponds. The filtering methods include many forms such as; centrifuges, conventional filters, chemically augmented filters using flocculants and coagulants, crystallizers, and evaporators.

Filtering systems have been to date rendered ineffective due to many reasons including; the high cost of chemical additives needed to supplement a conventional filtering process; the phenomena of poor hydraulic permeability of the suspended clays which quickly jam a conventional filter; and/or the high cost of conventional filters and their short production life. Evaporation techniques cannot service effectively the large volume of fluid that needs to be treated. Centrifuges can work but have proven to be a high maintenance and expensive process. Crystallizers in this application typically fail due to contamination issues and cost. A better, more robust and cost-effective system, is needed to help reduce the ecological damage inflicted by the continued growth of the tailings ponds in most mining activities including bitumen ore.

BRIEF SUMMARY

Various embodiments of the present disclosure include a system for the filtering of contaminated fluid. The system can include a fiber manufacturing plant. The system can include a filter system which utilizes a fiber filter produced in the fiber manufacturing plant to clean and recycle a contaminated fluid.

Various embodiments of the present disclosure include a system for the filtering of contaminated fluid. The system can include a fiber manufacturing plant. The system can include a filter system which utilizes a pre-filter screen which is movable and self-cleaning and a fiber filter produced in the fiber manufacturing plant to clean and recycle a contaminated waste fluid.

Various embodiments of the present disclosure include a system for the filtering of contaminated fluid. The system can include a plasma melter based fiber manufacturing plant. The system can include a filter system which utilizes a fiber filter produced in the plasma melter based manufacturing plant to clean and recycle a contaminated waste fluid.

Various embodiments of the present disclosure include a system for the filtering of contaminated fluid. The system can include a plasma and fossil fuel melter based fiber manufacturing plant. The system can include a filter system which utilizes a fiber filter produced in the plasma and fossil fuel melter based fiber manufacturing plant to clean and recycle a contaminated waste fluid.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a typical bitumen mining and separation process including tailing ponds, in accordance with embodiments of the present disclosure.

FIG. 2 depicts a cross section detail of a typical bitumen tailings pond, in accordance with embodiments of the present disclosure.

FIG. 3 depicts a second cross section detail of a bitumen tailings pond, in accordance with embodiments of the present disclosure.

FIGS. 4A and 4B depict a representation of a filter system, method, and apparatus that is in accordance with embodiments of the present disclosure in a closed or pressurized condition.

FIG. 5 depicts a representation of a filter system, method, and apparatus that is in accordance with embodiments of the present disclosure in an open or un-pressurized condition.

FIG. 6 depicts a complete filter plant that is in keeping with a method and apparatus that is in accordance with embodiments of the present disclosure.

FIG. 7 depicts a detail of the filter systems and transfer lines that are in keeping with a method and apparatus that is in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION

Embodiments of the present disclosure relate generally to a method, apparatus and system for the remediation and potential elimination of tailing ponds that can result from surface mining of natural resources such as bitumen or unconventional oil.

Embodiments of the present disclosure relate generally to a method, apparatus and system for the remediation and potential elimination of tailing ponds that result in many cases from surface mining of natural resources such as bitumen or unconventional oil. In all cases of this disclosure, the tailing pond contaminated fluid is filtered through a fiber filter. The fiber filter is produced from an inorganic such as melted beach sand. The sand is a by-product of the Clark Hot Water Extraction Process (CHWP) and typically is extracted from the tailing ponds. Other chemical additives such as lime sludge which are also a byproduct of bitumen extraction can be added to the inorganic to promote fiber production. Fiber production is established to produce a low cost and continuous filter element for the method, apparatus and system disclosed. The contaminated fluid is filtered through the produced fiber filter element, which is then deposited or shredded and deposited into a structurally stable land fill. Additional chemical additives such as surfactants, coagulants and flocculants can be added to tailings fluid to help promote filtering efficiency. Chemical additions, although possible, are preferably minimized due to their added operating expense and negative effect on the fluid's recycled performance. The disclosed process minimizes the need for additional chemicals due to its continuous, disposable, and effective filtering process. The disposable filter also becomes a 3 dimensional media used to stabilize the filtered mining byproducts for final disposition into a land fill.

FIG. 1 shows the process and volume flow of a typical bitumen extraction process in locations such as the Alberta Oil Sands and the resulting tailings pond from the extraction process. This process is generically referred to as the Clark Hot Water Extraction Process (CHWP).

Input stream 1 can include feed ore mined from the ground. It typically can contain 5 barrels (bbl) of solids, 1.1 bbl of bitumen and 0.5 bbl of water. However, the ratios of solids to bitumen to water are given for example only and can be varied. Makeup water stream 2 in a typical bitumen extraction process can include 2.6 bbl of additional fresh makeup water. As depicted, the makeup water from the makeup water stream 2 can be added in addition to recycled water from recycle stream 3. As further depicted, 7.1 bbl of recycled pond water is added to the makeup water. This slurry is then transported down a pipe (e.g., hydrotransport) to an extraction plant 5. The transportation of the slurry from a mine location to an extraction plant helps to start the bitumen separation process. In an example, the slurry can include 5 bbl of solids, 1.1 bbl of bitumen, and 10.2 bbl of water. In the extraction plant 5, heat, agitation and chemicals are added to further separate the bitumen from the balance of the ore. A froth is formed, which is separated from a fluid. The froth contains the desired bitumen product. The fluids contain the resultant unwanted clays, fines, sands and miscellaneous solids. The product froth continues through a further separation process, depicted as froth treatment 15, and a salable oil equivalent product is produced via the froth treatment and is stored in tank 6.

The waste fluid from the CHWP in conduit 16 can nominally be made up of 4.9 bbl of solids, 0.08 bbl of unrecovered bitumen and 9.4 bbl of contaminated waste fluid, in an example. The waste fluid is typically transferred onto dykes 11 where the heavy solids, such as sand, quickly precipitate out and are deposited in a mound of beach sand 8. Some re-usable or reclaimed water 9 (e.g., 7.1 bbl) in a reclaimed water zone quickly forms on top of the remaining tailings pond. The balance of the fluid can remain in a contaminated state of solids and fluid made up primarily of fine clays and water shown as contaminated material 10 (e.g., 0.3 bbl of solids and 1.7 bbl of water), which can stay in suspension for decades and potentially thousands of years.

FIG. 2 shows a detail of a tailings pond, reclaimed fluid 9′, and contaminated material made up of immature fine tailings 12 and mature fine tailings 17. The figures herein can depict elements that are the same or similar via use of a “prime” number. For example, the beach 8′ depicted in FIG. 2 can be the same or similar to the beach 8″ depicted in FIG. 3. The waste fluid is typically transferred onto dykes 11′ where the heavy solids, such as sand, quickly precipitate out and are deposited in a mound of beach sand 8′. Contaminated material 10 depicted in FIG. 1 is more accurately made up of at least two components shown as immature fine tailings 12 and mature fine tailings (MFT) 17, as depicted in FIG. 2. The slurry made up of contaminated material 10 is desired to mature from the immature fine tailings 12 and MFT 17, shown in FIG. 2, into a final configuration of free water or reclaimed water 9′ and MFT 17 only. As previously noted, this can take from decades to thousands of years. At the conclusion of this process, it is desired to remove the MFTs 17 and landfill them in a manner, which allows for an acceptable overburden load or compressibility. Unfortunately, for the MFTs 17 to become capable of carrying a load, it can take the extended times already noted. In the meantime, the tailing ponds must exist and in most cases grow into an ever larger environmental liability.

FIG. 3 depicts how embodiments of the present disclosure relate generally to a method, apparatus and system for the remediation and potential elimination of tailing ponds that result in many cases from surface mining of natural resources, such as bitumen or unconventional oil. Immature fine tailings (IMF) 12 and MFT 17 (FIG. 2) in the disclosed method, apparatus and system are never allowed to separate out into the previously described zones.

Any fast-developing free water (e.g., reclaimed water 9″) in the reclaimed water zone is extracted in a conduit (not shown) for recycling to the CHWP to reduce the filtering process requirements of the disclosed method, apparatus and system. A new zone, which is made up of fluids and fines shown as extraction zone 13 in FIG. 3 is tapped as an extraction point 14 through which fluid can be extracted from the extraction zone 13 and/or from the tailings pond. For example, the IMF 12 and MFT 17 are not allowed to separate out in an extraction zone 13. The extracted fluid can consequently provide a feedstock for the disclosed method, apparatus and system. A man made buffering pool can be substituted for a tailings pond and can be sized large enough for the heavy partials such as the beach sands to precipitate and later be utilized in the filter making process. Free water may or may not be available depending on the size of the buffer pool and consequently the available settling time. The pools could be lined with clay, plastic, concrete or any other viable isolation material. This much smaller buffering pool would eliminate the need for a tailings pond.

FIG. 4 shows the resulting fluid 13′ from pond extraction point 14 (FIG. 3) being delivered to housing 17 which is a component of a fluid filtering station described by FIG. 4. Additional chemical additives, such as surfactants, coagulants and flocculants can be added to tailings fluid 13′ to help promote filtering efficiency. The effectiveness of prescreen 18 and filter material 20 (e.g., fiber filter blanket) promotes the minimization of any needed additional chemicals. For example, the prescreen 18 can be disposed over the filter material 20 and can catch larger diameter particles, while the filter material 20 can filter the particles that pass through the prescreen 18.

The prescreen 18 can be a pre-filter and can be formed from a mesh, which can be sized and configured for 40 to 400 microns of filtering capability and can be layered on top of the filter material 20. In some embodiments, the prescreen 18 can be sized and configured for approximately 100 to 200 microns of filtering capability. The filter material 20 can be produced by a vitrifying process. The heat to produce the vitrifying melt could be generated by any heat source such as a fossil fuel, which could be coal, natural gas, well head gas, propane, butane, or any other heat producing fuel, or by an alternative heat source such as electricity, which could be in the form of a plasma heat generator, or a combination of all the above. The fiber produced to form the filter material 20 is compressed by housing 17, imparting a force on prescreen 18, which then imparts a resultant force and compression on the filter material 20. In some embodiments, the prescreen 18 can be formed from a rigid and/or semi-rigid material, such as a metal and/or plastic. Fluid 13′ can be pressurized to force the contaminated fluid through prescreen 18 and finally through filter material 20. The pressure, flow, or both pressure and flow, of the fluid 13′ in housing 17 can be monitored against limits to end the filter process. For example, if the pressure increases to a defined limit and/or the flow decreases to a defined limit, the process can be stopped. The filter process may be able to cycle a number of times without replacing the filter fiber by advancing the prescreen 18 off of feed roll 19 past scraper 26 to extract the contaminant 27 into a catch basin (not shown). Air blow off 29 may be optionally added in addition to or in place of the scraper 26 to assist in the extraction process. The pre-filter can be taken up and stored on spool 25. In an example, when the filter process cycles, the housing 17 can be retracted, as further depicted and described in relation to FIG. 5.

Support 28A can be a foundation or back support for the filter material 20 and can be manufactured many different ways. In an example, the support 28A can be a large mesh screen or it can be configured as a bar support arrangement, for example a bar support 28B, as shown in FIG. 4B. FIG. 4B depicts a top view of the bar support 28B. For example, the bar support 28B can include an outer frame 31 that houses a plurality of bars (e.g., bar 35) that extend across and/or are mounted to the outer frame 31. Housing support 22 can be disposed below the filter material 20, the prescreen 18, and the support 28A. In some embodiments, a vacuum can be created in the housing support 22 to help draw fluid through the prescreen 18 and the filter material 20, into the housing support 22. In some embodiments, the housing support 22 can be kept at atmospheric conditions or even above atmospheric conditions. As the delta pressure between fluid 13 and housing support 22 is increased, the produced filter flow volume can be increased. Filtered fluid 23 to be returned to the CHWP can pass from the housing support 22 through a conduit (e.g., filtered fluid conduit) formed in the housing support 22. Overflow or“House Keeping Fluid” is extracted at conduit 30 and returned to flow 13′.

FIG. 5 shows the filter assembly depicted in FIG. 4A in the retracted position and depicts the same or similar elements as depicted in FIG. 4A. For example, in the retracted position, the flow of fluid 13″ is halted and housing 17′ is retracted from the prescreen 18′ and filter material 20′. The prescreen 18′ can be advanced and taken up on roll 25′, as previously described, to provide a new portion of prescreen 18′. Upon advancement of the prescreen 18′, housing 17′ can then be advanced to the position in FIG. 4A and the filtering process can be continued by reinitiating flow of fluid 13′. In the retracted position of housing 17′ shown in FIG. 5, filter material 20′ may also be advanced to expose a new filter element to fluid 13′. For example, in some embodiments, a new portion of filter material 20′ can be advanced in a similar manner as that associated with the prescreen 18′.

FIG. 6 shows a complete filtering plant as disclosed in this method, apparatus and system. The example shown uses both a fossil fuel and electricity converted to thermal plasma to produce the heat required to melt and vitrify a feedstock for the production of a fiber filter (e.g., filter material 20″). Filter system 47, such as that described and previously denoted in FIGS. 4A to 5, is provided and can produce filtered water 23′ from fluid 13′″. A tailings pond, from which fluid 13′″ can be provided, as denoted in FIGS. 1, 2 and 3, has not been shown to promote drawing simplicity.

An inorganic feedstock (e.g., fiber feedstock) such as beach sand 8 in FIGS. 1, 2 and 3 and other chemical supplements such as lime sludge, which is a byproduct of oil recovery, is deposited and batched on loading floor 48. Those skilled in the art will recognize there are many accepted ways to mix or batch this feedstock queuing and loading process. A manual front end loader 42 is shown as a simple example. The fiber feedstock will many times be placed on transfer line 39 to be processed through dryer 36. The dryer 36 can typically run off waste heat from conduit 43, which is a byproduct of an afterburner 44. Combustion air 37 can be pre-heated through dryer 36 and can extract the inorganic fraction of the fiber feedstock, which can be transferred through conduits 40 and 41 and used to help generate heat in this example in plasma melter 32. Additional fuel 51, such as a fossil fuel, can be injected into plasma chamber 32 through fuel conduit 52. The exhaust gas from the melt process is post processed through conventional clean up processes before it is released to the atmosphere.

Fiber spinner 53 can be fed with the vitrified melt produced in melter 32 to produce an interwoven fiber, which can be collected in a blanket form in drum collector 33. Fiber spinner can be a spinner such as that disclosed in WO application no. 2016/164901, which is incorporated by reference as though fully set forth herein. This interwoven fiber blanket can be controlled in depth by the melting and spinning process and can be controlled in filter characteristics by the fiber length and the later fiber blanket compression in filter unit 47 (e.g., the fiber blanket compression via the housing 17 in FIGS. 4A and 5). The depth of the fiber blanket can be in a range from 5 centimeters (cm) to 30 cm and preferably from 15 cm to 20 cm. The fiber strand length in the blanket can be in a range from 0.25 cm to 3 cm, but is preferred from 1 cm to 1.75 cm. Transfer line 54 moves the fiber blanket from the drum collector and forms the blanket in a width that can be in a range from 0.6 m to 3 m and preferably in a range from 1 meter (m) to 2 m. Transfer line 54 moves the blanket to cutter station 34, which cuts the blanket to a predetermined length. The length can be in a range from 1 m to 4 m and preferably from 1 m to 2 m. The sized filter blanket proceeds to buffer line 20″ and into filter stations 46. Six filter stations are shown in FIG. 6, however, any number of filter stations 46 that can be supported by the melter can be used. In some embodiments, the number of filter stations 46 can be in a range from 5 to 25 filter stations 46 and preferably from 6 to 12 filter stations 46. Fluid 13′″ is transported through conduit 49 to filter systems 47 to produce recycled fluid 23, which can be repurposed in the CHWP.

FIG. 7 is a detailed image of the filtering area that includes filter stations 46 previously described herein, for example in relation to FIG. 6. The pre-sized filter blankets from cutter 34′ are transferred into buffer areas 20′″ via the main transfer line. Off take stations 55 can rout the filter blanket towards filter unit 47′ via off take buffer area 20-1 or pass the blanket through to location 56 to have access to additional filter stations. One filter station line has been described and detailed but many can be supported by the same principals as already discussed. In an example, filter blanket can be passed through buffer area 20-2 on its way to additional filter stations and/or to storage area, for example, via buffer output 57. After the filter blanket is spent in station 47′, as previously described, the blanket can be ejected to line 58 which could eject the complete filter element (not shown) or feed the element (as shown) into bulk shredder 59. Bulk shredder 59 cuts the blanket into a size that is complementary to the physical traits of the fiber which can be in a range from 2.5 cm to 13 cm pieces and preferably in a range from 5 cm to 8 cm pieces. Upon shredding, these fiber pieces which carry away the fine clays and silt from fluid 13′″ in the filtering process are now able to have acceptable compaction and compressive strength and can be ejected via fiber output 60. The three-dimensional interwoven fiber acts as a binding agent for the mining waste. The filter byproduct can now be deposited in a conventional landfill to be covered with overburden or load bearing structures such as roads. The spent filters could also be recycled through the melter to manufacture new clean filter elements.

Embodiments are described herein of various apparatuses, systems, and/or methods. Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments as described in the specification and illustrated in the accompanying drawings. It will be understood by those skilled in the art, however, that the embodiments may be practiced without such specific details. In other instances, well-known operations, components, and elements have not been described in detail so as not to obscure the embodiments described in the specification. Those of ordinary skill in the art will understand that the embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and do not necessarily limit the endoscope of the embodiments, the scope of which is defined solely by the appended claims.

Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment”, or the like, means that a particular feature, structure, or characteristic described in connection with the embodiment(s) is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment,” or the like, in places throughout the specification, are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features, structures, or characteristics of one or more other embodiments without limitation given that such combination is not illogical or non-functional. 

What is claimed:
 1. A system for the filtering of contaminated fluid, comprising: a fiber manufacturing plant, wherein the fiber manufacturing plant includes a melter and a spinner operable to produce a fiber filter blanket; and a filter system that includes a filter station operably connected to the fiber manufacturing plant via a transfer line, wherein: the fiber filter blanket is transferred from the fiber manufacturing plant to the filter station via the transfer line, and the filter system is configured to clean a contaminated fluid with the filter blanket, wherein the contaminated fluid is provided to the filter system via an inlet.
 2. The system for the filtering of contaminated fluid of claim 1, where the filtering system is configured to shred a spent fiber filter with a shredder and re-melt the spent fiber filter with a plasma and fossil fuel based melter included in the manufacturing plant to manufacture a new fiber filter.
 3. The system for filtering of contaminated fluid of claim 1, further comprising a filter support feed roll, wherein the fiber filter is configured to be continually advanced over a filter support via the feed roll.
 4. A system for the filtering of contaminated fluid, comprising: a fiber manufacturing plant including a melter and a cutter operable to pre-size a fiber filter blanket produced in the plant; and a filter system operably connected to the fiber manufacturing plant via a transfer line, wherein: the filter system includes a pre-filter screen, which is movable, and a fiber filter, the fiber filter is configured to clean a contaminated waste stream provided to the filter system via an inlet, and the fiber filter includes the pre-sized fiber filter blanket that is produced in the fiber manufacturing plant, wherein the fiber filter blanket is transferred from the fiber manufacturing plant to the filter system via the transfer line.
 5. The system of claim 4, wherein a component of the fiber filter includes a recycled inorganic material.
 6. The system of claim 4, wherein a component of the fiber filter includes a recycled inorganic material, including beach sand.
 7. The system of claim 4, wherein a component of the fiber filter includes a recycled chemical additive.
 8. The system of claim 4, wherein a component of the fiber filter includes a recycled chemical additive that includes lime sludge.
 9. A system for the filtering of contaminated fluid, comprising: a fiber manufacturing plant that includes a melter configured to produce a melt, wherein the fiber manufacturing plant further includes a structure operable to produce a filter blanket from the melt; and a filter system that includes a filter station operably connected to the fiber manufacturing plant via a transfer line, wherein: the filter system includes a fiber filter configured to clean contaminated fluid provided to the filter system via an inlet, and the fiber filter includes the fiber blanket that is produced in the fiber manufacturing plant, wherein the fiber filter blanket is transferred from the fiber manufacturing plant to the filter system via the transfer line.
 10. The system of claim 9, wherein the fiber manufacturing plant is configured to recycle a spent fiber filter through the melter to manufacture a new filter.
 11. The system for the filtering of the contaminated fluid of claim 10, wherein the filter system is configured to receive the contaminated fluid as a byproduct of a mining industry via a conduit.
 12. The system for the filtering of the contaminated fluid of claim 10, wherein the filter system is configured to receive the contaminated fluid as a byproduct of an oil mining industry via a conduit.
 13. The system for the filtering of the contaminated fluid of claim 10, wherein the filter system is configured to draw the contaminated fluid from a tailings pond, via a conduit.
 14. The system for the filtering of the contaminated fluid of claim 10, wherein the filter system is configured to draw the contaminated fluid from a buffering pool, via a conduit.
 15. The system of claim 10, wherein a component of the fiber filter includes an inorganic material. 